U.S. patent application number 13/697324 was filed with the patent office on 2013-03-07 for back side protective sheet for solar cell and solar cell module comprising the same.
This patent application is currently assigned to TOYO ALUMINIUM KABUSHIKI KAISHA. The applicant listed for this patent is Daisuke Maeda, Takanobu Terasawa. Invention is credited to Daisuke Maeda, Takanobu Terasawa.
Application Number | 20130056066 13/697324 |
Document ID | / |
Family ID | 44914274 |
Filed Date | 2013-03-07 |
United States Patent
Application |
20130056066 |
Kind Code |
A1 |
Maeda; Daisuke ; et
al. |
March 7, 2013 |
BACK SIDE PROTECTIVE SHEET FOR SOLAR CELL AND SOLAR CELL MODULE
COMPRISING THE SAME
Abstract
Provided are a back side protective sheet for a solar cell
capable of enhancing adherence to an EVA resin as a filler used to
seal solar cell elements and of maintaining a weather resistance
over a long period of time; and a solar cell module including the
back side protective sheet for a solar cell. The back side
protective sheet (10) for a solar cell, which is disposed on a back
side of a solar cell module, includes: a first film (11)
constituted of a laminated body formed by causing a linear
low-density polyethylene layer (111), an interposing resin layer
(113), and a linear low-density polyethylene layer (112) to
directly contact each other in order; and a second film (12)
laminated on the first film (11), with an adhesive layer (13)
interposed between the first film (11) and the second film (12).
The interposing resin layer (113) is formed of one kind of a resin
selected from the group consisting of high-density polyethylene,
polypropylene, a cycloolefin polymer, and a methacrylate resin.
Inventors: |
Maeda; Daisuke; (Osaka-shi,
JP) ; Terasawa; Takanobu; (Osaka-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Maeda; Daisuke
Terasawa; Takanobu |
Osaka-shi
Osaka-shi |
|
JP
JP |
|
|
Assignee: |
TOYO ALUMINIUM KABUSHIKI
KAISHA
Osaka-shi, Osaka
JP
|
Family ID: |
44914274 |
Appl. No.: |
13/697324 |
Filed: |
April 19, 2011 |
PCT Filed: |
April 19, 2011 |
PCT NO: |
PCT/JP2011/059594 |
371 Date: |
November 9, 2012 |
Current U.S.
Class: |
136/256 ;
428/483; 428/516 |
Current CPC
Class: |
Y02E 10/50 20130101;
B32B 27/308 20130101; B32B 7/12 20130101; Y10T 428/31797 20150401;
Y10T 428/31913 20150401; B32B 27/32 20130101; B32B 27/08 20130101;
B32B 2307/712 20130101; H01L 31/049 20141201; B32B 27/325 20130101;
B32B 2457/12 20130101; H01L 31/02013 20130101 |
Class at
Publication: |
136/256 ;
428/516; 428/483 |
International
Class: |
H01L 31/0203 20060101
H01L031/0203; B32B 27/32 20060101 B32B027/32 |
Foreign Application Data
Date |
Code |
Application Number |
May 12, 2010 |
JP |
2010-109857 |
Claims
1-6. (canceled)
7. A back side protective sheet (10) for a solar cell disposed on a
back side of a solar cell module, comprising: a first film (11)
constituted of a laminated body formed by causing linear
low-density polyethylene (111), an interposing resin (113), and
linear low-density polyethylene (112) to directly contact each
other in order; and a second film (12) laminated on the first film
(11), with an adhesive layer (13) interposed between the first film
(11) and the second film (12), the interposing resin (113) being
one kind of a resin selected from the group consisting of
polypropylene, a cycloolefin polymer, and a methacrylate resin.
8. The back side protective sheet (10) for a solar cell according
to claim 7, wherein a density of the linear low-density
polyethylene is 0.91 g/cm.sup.3 or more and 0.93 g/cm.sup.3 or
less.
9. The back side protective sheet (10) for a solar cell according
to claim 7, wherein the adhesive layer (13) is a urethane-based
adhesive layer.
10. The back side protective sheet (10) for a solar cell according
to claim 7, wherein the linear low-density polyethylene includes
0.1% by mass or more and 30% by mass or less of an inorganic
ultraviolet ray absorber having an average particle diameter of 0.1
.mu.m or more and 5 .mu.m or less.
11. The back side protective sheet (10) for a solar cell according
to claim 7, wherein the second film (12) is formed of a
fluorine-based resin.
12. A solar cell module (100) comprising: a filler (7) formed of an
ethylene-vinyl acetate copolymer resin disposed to seal solar cell
elements (1); and the back side protective sheet (10) for a solar
cell according to claim 7, fixedly attached on an outer surface of
the filler (7) on a back side of the solar cell module (100).
Description
TECHNICAL FIELD
[0001] The present invention relates generally to a back side
protective sheet for a solar cell disposed on a back side of a
solar cell module and to a solar cell module including the back
side protective sheet for a solar cell. More particularly, the
present invention relates to a back side protective sheet for a
solar cell, which has a long-term weather resistance, and to a
solar cell module including the back side protective sheet for a
solar cell.
BACKGROUND ART
[0002] Because of the nature of a solar cell module, it is often
the case that a solar cell module is installed outdoors. Therefore,
in order to protect solar cell elements, electrodes, wires, and the
like, for example, a transparent glass plate is disposed on a front
side thereof and, for example, a laminated sheet of aluminum foil
and a resin film, a laminated sheet of resin films, or the like is
disposed on a back side thereof.
[0003] Japanese Patent Application Laid-Open Publication No.
2010-27714 (Patent Literature 1) has proposed a laminated sheet of
aluminum foil and a resin film as a back side protective sheet for
a solar cell which is excellent in a moisture proof property.
[0004] However, because in the back side protective sheet for a
solar cell proposed in Japanese Patent Application Laid-Open
Publication No. 2010-27714 (Patent Literature 1), an electrical
short circuit between solar cell elements and the aluminum foil is
likely to occur and corrosion of the aluminum foil is likely to be
caused by a long-term use, a laminated sheet of resin films has
been widely used as a back side protective sheet for a solar
cell.
[0005] Solar cell elements are sealed by a filler of an
ethylene-vinyl acetate copolymer (EVA) resin or the like and are
disposed so as to be sandwiched between a transparent glass plate
on the above-mentioned front side and a laminated sheet on a back
side. Accordingly, the back side protective sheet for a solar cell
is caused to adhere to an outer surface of the ethylene-vinyl
acetate copolymer (EVA) resin by a hot-press. For example, Japanese
Patent Application Laid-Open Publication No. 2008-211034 (Patent
Literature 2) has proposed a back side protective sheet for a solar
cell capable of enhancing adherence to the EVA resin as the filler
used to seal the solar cell elements, of maintaining the weather
resistance over a long period of time, and of reducing a weight.
This back side protective sheet for a solar cell includes: a first
film which contains linear low-density polyethylene having a
density 0.91 g/cm.sup.3 or more and 0.93 g/cm.sup.3 or less; and a
second film which contains polyvinylidene fluoride and polymethyl
methacrylate and is laminated on the first film.
[0006] Along with the spread of solar power generation, a
considerable long-term service life, which is a period of several
decades, is expected of solar cells to be installed in a location
having difficulties in installing the solar cells, such as a high
place, in particular. However, the back side protective sheet for a
solar cell proposed in Japanese Patent Application Laid-Open
Publication No. 2008-211034 (Patent Literature 2) has a problem in
that it is difficult to maintain a weather resistance over a long
period of time of the several decades.
CITATION LIST
Patent Literature
[0007] Patent Literature 1: Japanese Patent Application Laid-Open
Publication No. 2010-27714
[0008] Patent Literature 2: Japanese Patent Application Laid-Open
Publication No. 2008-211034
SUMMARY OF THE INVENTION
Technical Problem
[0009] Therefore, objects of the present invention are to provide a
back side protective sheet for a solar cell capable of enhancing
adherence to an EVA resin as a filler used to seal solar cell
elements and of maintaining a weather resistance over a long period
of time; and a solar cell module including the back side protective
sheet for a solar cell.
Solution to Problem
[0010] A back side protective sheet for a solar cell according to
the present invention, which is disposed on a back side of a solar
cell module, includes: a first film constituted of a laminated body
formed by causing linear low-density polyethylene, an interposing
resin, and linear low-density polyethylene to directly contact each
other in order; and a second film laminated on the first film, with
an adhesive layer interposed between the first film and the second
film. The interposing resin is one kind of a resin selected from
the group consisting of high-density polyethylene, polypropylene, a
cycloolefin polymer, and a methacrylate resin.
[0011] In the back side protective sheet for a solar cell according
to the present invention, it is preferable that a density of the
linear low-density polyethylene is 0.91 g/cm.sup.3 or more and 0.93
g/cm.sup.3 or less.
[0012] In the back side protective sheet for a solar cell according
to the present invention, it is preferable that the adhesive layer
is a urethane-based adhesive layer.
[0013] In the back side protective sheet for a solar cell according
to the present invention, it is preferable that the linear
low-density polyethylene includes 0.1% by mass or more and 30% by
mass or less of an inorganic ultraviolet ray absorber having an
average particle diameter of 0.1 .mu.m or more and 5 .mu.m or
less.
[0014] In the back side protective sheet for a solar cell according
to the present invention, it is preferable that the second film is
formed of a fluorine-based resin.
[0015] A solar cell module according to the present invention
includes: a filler formed of an ethylene-vinyl acetate copolymer
resin disposed to seal solar cell elements; and the back side
protective sheet for a solar cell, having any of the
above-described features, fixedly attached on an outer surface of
the filler on a back side of the solar cell module.
Advantageous Effects of the Invention
[0016] In a back side protective sheet for a solar cell according
to the present invention, linear low-density polyethylene included
in a first film is excellent in adherence to a filler formed of an
ethylene-vinyl acetate copolymer resin disposed to seal solar cell
elements and is capable of maintaining the adherence over time. In
addition, as an interposing resin included in the first film, one
kind of a resin selected from the group consisting of high-density
polyethylene, polypropylene, a cycloolefin polymer, and a
methacrylate resin is used, thereby enabling the prevention of
deterioration of the first film caused by hydrolysis resulting from
long-term moisture absorption and thermal action. The linear
low-density polyethylene is excellent in adherence to the
above-mentioned interposing resin.
[0017] Accordingly, according to the present invention, the
adherence between an EVA resin as the filler used to seal the solar
cell elements and the back side protective sheet can be enhanced
and a weather resistance can be maintained over a long period of
time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a schematic diagram illustrating a cross section
structure of a solar cell module to which a back side protective
sheet for a solar cell, as one embodiment according to the present
invention, is applied.
[0019] FIG. 2 shows a cross section view of the back side
protective sheet for a solar cell, as the one embodiment according
to the present invention.
[0020] FIG. 3 is a cross-section view illustrating one comparison
form of a back side protective sheet for a solar cell.
[0021] FIG. 4 is a cross-section view illustrating another
comparison form of a back side protective sheet for a solar
cell.
DESCRIPTION OF EMBODIMENTS
[0022] FIG. 1 is a schematic diagram illustrating a cross section
structure of a solar cell module to which a back side protective
sheet for a solar cell, as one embodiment according to the present
invention, is applied.
[0023] As shown in FIG. 1, a multitude of solar cell elements 1 are
arranged in the solar cell module 100. These solar cell elements 1
are electrically connected to each other via electrodes 2 by
connection wires 3. In the whole solar cell module 100, terminals 5
are led out to a back side thereof by lead wires 4, and the
terminals 5 are housed in a terminal box 6. A filler 7 constituted
of an ethylene-vinyl acetate copolymer (EVA) resin is disposed to
seal the multitude of solar cell elements 1. On an outer surface of
the filler 7, which is located on a light receiving surface side of
the solar cell module 100, a transparent glass layer 8 is fixedly
attached. On an outer surface of the filler 7, which is located on
an installation surface side of the solar cell module 100, the back
side protective sheet 10 for a solar cell is fixedly attached. On
side surfaces of the solar cell module 100, a frame member 9 formed
of aluminum is attached via a sealant.
[0024] FIG. 2 shows a cross section view of the back side
protective sheet for a solar cell, as the one embodiment according
to the present invention.
[0025] As shown in FIG. 2, in the back side protective sheet 10 for
a solar cell, a first film 11 and a second film 12 are laminated in
order from an inner layer disposed on a side (inner side)
relatively close to the solar cell module 100. Between the first
film 11 and the second film 12, a urethane adhesive layer 13 is
disposed. The first film 11 is fixedly attached so as to abut a
surface of the filler 7. This attachment is conducted by using a
hot-press. The second film 12 is disposed in an outermost layer of
the back side protective sheet 10 for a solar cell. The first film
11 includes: linear low-density polyethylene layers 111 and 112 and
an interposing resin layer 113 sandwiched between the linear
low-density polyethylene layers 111 and 112. In other words, in the
first film 11, the linear low-density polyethylene layer 111, the
interposing resin layer 113, and the linear low-density
polyethylene layer 112 are formed so as to directly contact each
other in order. The interposing resin layer 113 is formed of one
kind of a resin selected from the group consisting of high-density
polyethylene, polypropylene, a cycloolefin polymer, and a
methacrylate resin.
[0026] (First Film)
[0027] The linear low-density polyethylene layer 111 serves to
enhance adherence between a sealant such as the EVA resin and the
interposing resin layer 113. The linear low-density polyethylene
layer 112 serves to enhance adherence with the interposing resin
layer 113. It is preferable that a density of the linear
low-density polyethylene is 0.91 g/cm.sup.3 or more and 0.93
g/cm.sup.3 or less.
[0028] The one kind of a resin selected from the group consisting
of the high-density polyethylene (PE), the polypropylene (PP), the
cycloolefin polymer (CPE), and the methacrylate resin (PMMA) is
used as the interposing resin layer 113, thereby enabling the
prevention of deterioration of the first film 11 caused by
hydrolysis resulting from long-term moisture absorption and thermal
action. Each of these resins is an olefin resin, which is referred
to as a non-polar olefin resin or a low-polarity olefin resin and
has no functional groups having a polar character or does not have
many reactive functional groups, has a property hardly causing the
hydrolysis due to a low moisture absorption property thereof. In
particular, since the cycloolefin polymer is a hydrocarbon-based
polymer having an alicyclic structure as a ring-opening polymer of
the cycloolefin, the cycloolefin polymer constantly has a non-polar
structure.
[0029] In contrast to this, as an olefin resin having a high polar
character (in other words, which is not the non-polar olefin resin
or not the low-polarity olefin resin), polyester such as
polyethylene terephthalate can be cited. The resin having the high
polar character easily reacts with a solvent having a polar
character, that is, water. Therefore, for example, the polyethylene
terephthalate which is one example of the resin having the polar
character reacts with the water and generates terephthalic acid.
Because the generation of this terephthalic acid exerts an
influence on a molecular structure of the polyethylene
terephthalate, a mechanical strength, a moisture proof property,
and the like of film are reduced.
[0030] The non-polar or low-polarity olefin resin of which the
interposing resin layer 113 is formed is inferior in adhesiveness
with an adhesive, having the polar character, such as a
polyurethane-based adhesive widely used as a dry laminating
adhesive in particular, as compared with a resin having the high
polar character such as the polyethylene terephthalate. Therefore,
in the first film 11, the linear low-density polyethylene layer
111, the interposing resin layer 113, and the linear low-density
polyethylene layer 112 are formed so as to directly contact each
other in order without interposing an adhesive layer. The linear
low-density polyethylene is an olefin resin having a multipolar
character and exhibits favorable adhesiveness with any of a
non-polar olefin-based resin, a polyurethane-based adhesive, or the
EVA.
[0031] A method for configuring the first film 11 may be a method
in which the interposing resin layer 113 is formed to be film and
concurrently therewith, the linear low-density polyethylene layers
111 and 112 are formed on both sides of the formed film.
Specifically, by employing a co-extrusion method in which a T-die
film formation method or an inflation film formation method is
adopted, a coating method, or the like, the linear low-density
polyethylene layer 111, the interposing resin layer 113, and the
linear low-density polyethylene layer 112 may be concurrently
caused to adhere closely to each other, thereby forming the first
film 11. In particular, since when the co-extrusion method is
employed, it is easy to control a thickness of each of the resin
layers, a laminated film having a large width can be stably
obtained.
[0032] It is only required that a thickness of the interposing
resin layer 113 is 20 .mu.m or more and 200 .mu.m or less. It is
preferable that the thickness thereof is 50 .mu.m or more and 150
.mu.m or less, and it is more preferable that the thickness thereof
is 80 .mu.m or more and 150 .mu.m or less. If the thickness of the
interposing resin layer 113 is less than 20 .mu.m, an effect of a
moisture proof property, attained by the interposing resin layer
113, is not sufficient. If the thickness of the interposing resin
layer 113 exceeds 200 .mu.m, the effect of the moisture proof
property, attained by the interposing resin layer 113, becomes
saturated. A coloring agent may be added to the interposing resin
layer 113, thereby configuring a colored film.
[0033] Each of the linear low-density polyethylene layers 111 and
112 may include 0.1% by mass or more and 30% by mass or less of an
inorganic ultraviolet ray absorber having an average particle
diameter of 0.1 .mu.m or more and 5 .mu.m or less. As the inorganic
ultraviolet ray absorber contained in each of the linear
low-density polyethylene layers 111 and 112, titanium oxide, zinc
oxide, zirconium oxide, calcium carbonate, cerium oxide, aluminum
oxide, silica, iron oxide, carbon, and the like are cited, and the
titanium oxide or the carbon is preferably used. If the average
particle diameter of the ultraviolet ray absorber exceeds 5 .mu.m,
dispersibility in each of the linear low-density polyethylene
layers 111 and 112 is worsened, whereby it is likely that an effect
of uniform ultraviolet ray absorption cannot be obtained. In
addition, if the average particle diameter of the ultraviolet ray
absorber is less than 0.1 .mu.m, a price per unit weight is
increased. If the content of the inorganic ultraviolet ray absorber
is less than 0.1% by mass, the effect of the ultraviolet ray
absorption is not sufficient, and it is likely that the back side
protective sheet 10 for a solar cell is yellowed. In addition, if
the content of the inorganic ultraviolet ray absorber exceeds 30%
by mass, it is likely that adherence thereof with the sealant, the
adhesive layer, and the interposing resin layer is reduced.
[0034] It is only required that a thickness of the linear
low-density polyethylene layer 111 is 30 .mu.m or more and 150
.mu.m or less, and it is preferable that the thickness thereof is
30 .mu.m or more and 80 .mu.m or less. It is only required that a
thickness of the linear low-density polyethylene layer 112 is 10
.mu.m or more and 150 .mu.m or less, and it is preferable that the
thickness thereof is 20 .mu.m or more and 80 .mu.m or less. If the
thickness of the linear low-density polyethylene layer 111 is less
than 30 .mu.m or the thickness of the linear low-density
polyethylene layer 112 is less than 10 .mu.m, it is likely that
adherence thereof with the sealant or the adhesive layer is
reduced. In addition, in a case where each of the linear
low-density polyethylene layers 111 and 112 includes the
ultraviolet ray absorber, if the thickness of the linear
low-density polyethylene layer 111 is less than 30 .mu.m or the
thickness of the linear low-density polyethylene layer 112 is less
than 10 .mu.m, an effect of the ultraviolet ray absorption,
attained by the ultraviolet ray absorber, is not sufficient, and it
is likely that a part of transmitted ultraviolet rays promotes
deterioration of the back side protective sheet 10 for a solar
cell. If the thickness of each of the linear low-density
polyethylene layers 111 and 112 exceeds 150 .mu.m, the adherence
thereof with the sealant or the adhesive layer and the effect of
the ultraviolet ray absorption become saturated. A coloring agent
is added to each of the linear low-density polyethylene layers 111
and 112, thereby configuring colored films.
[0035] (Second Film)
[0036] A weather resistance and an electrical insulating property
are required of the second film 12. A polyester film such as
polyethylene naphthalate (PEN) and polyethylene terephthalate
(PET); a fluorine-based film such as polyvinylidene fluoride
(PVDF), polyvinyl fluoride (PVF), and ethylene-tetrafluoroethylene
(ETFE); a polyolefin film such as polyethylene and polypropylene; a
polystyrene film; a polyamide film; a polyvinyl chloride film; a
polycarbonate film; a polyacrylonitrile film; a polyimide film; or
the like can be used. In addition, a laminated film may constitute
the second film 12, instead of a single-layer film.
[0037] In a case where the laminated film constitutes the second
film 12, it is preferable that a film excellent in the weather
resistance and a film excellent in the electrical insulating
property are laminated. In this case, the film excellent in the
electrical insulating property is laminated on a side of the first
film 11. As the film excellent in the weather resistance, it is
preferable that the fluorine-based film, in particular, whose
thickness is 20 .mu.m or more and 150 .mu.m or less is used. As the
film excellent in the electrical insulating property, the
polyethylene terephthalate (PET), in particular, whose thickness is
100 .mu.m or more and 250 .mu.m or less is preferably used.
[0038] (Adhesive Layer)
[0039] The first film 11 and the second film 12 are laminated by
using an urethane adhesive and employing a dry lamination method.
As the urethane adhesive, although there are a two-part curable
urethane adhesive, a polyether urethane adhesive, a polyester
polyurethane polyol adhesive, and the like, in particular, it is
preferable that the two-part curable urethane adhesive is used.
[0040] The first film 11 and the second film 12 can be laminated by
employing the heretofore known method. For example, as described
above, a method in which the first film 11 and the second film 12
are laminated with the adhesive layer 13 interposed therebetween as
shown in FIG. 2 by using the urethane adhesive and employing the
dry lamination method is employed. In addition to the
above-mentioned method, a co-extrusion method, an extrusion coat
method, a thermal lamination method using an anchor coat agent, or
the like may be adopted to laminate the first film 11 and the
second film 12.
EXAMPLES
[0041] Test samples of examples, comparison examples, and a
reference example of the back side protective sheet for a solar
cell were prepared as described below.
Example 1
[0042] To 100 parts by mass of a polyethylene resin (ULTZEX
manufactured by Mitsui Chemicals, Inc.) having a density of 0.93
g/cm.sup.3, 4.5 parts by mass of titanium oxide particles having an
average particle diameter of 0.3 .mu.m were added and the resultant
was sufficiently kneaded, thereby preparing a linear low-density
polyethylene composition. With an interposing resin sandwiched
between these linear low-density polyethylene compositions, film
formation was conducted by means of a T-die extruder by employing a
co-extrusion method, and as shown in FIG. 2, a first film 11 was
prepared such that thicknesses of a linear low-density polyethylene
layer 111, an interposing resin layer 113, and a linear low-density
polyethylene layer 112 were 50 .mu.m, 100 .mu.m, and 50 .mu.m,
respectively. As the interposing resin layer 113, a high-density
polyethylene (Novatec HD manufactured by Japan Polyethylene
Corporation) was used.
[0043] Next, polyvinyl fluoride (PVF) (Tedlar manufactured by
DuPont Co., Ltd.) having a thickness of 38 .mu.m was used as a
second film 12. The above-mentioned first film 11 and second film
12 were bonded by using a dry laminating adhesive and employing a
dry lamination method, thereby preparing a back side protective
sheet 10 for a solar cell. As an adhesive layer 13, a
polyurethane-based adhesive obtained by mixing 100 parts by mass of
"product name: TAKELAC A315" and 10 parts by mass of "product name:
TAKENATE A50", both of which were manufactured by Mitsui Chemicals
Polyurethanes Co., Ltd., was prepared with a solid content coated
amount of 5 g/m.sup.2.
Example 2
[0044] As an interposing resin layer 113, polypropylene (Novatec PP
manufactured by Japan Polypropylene Corporation) was used. In
addition, as a second film 12, polyvinylidene fluoride (PVDF)
(manufactured by DENKI KAGAKU KOGYO KABUSHIKI KAISHA) having a
thickness of 40 .mu.m was used. The other configuration was made
the same as that of example 1, thereby preparing a back side
protective sheet 10 for a solar cell.
Example 3
[0045] As an interposing resin layer 113, cycloolefin polymer
(ZEONOR manufactured by ZEON CORPORATION) was used. In addition, as
a second film 12, polyvinylidene fluoride (PVDF) (manufactured by
DENKI KAGAKU KOGYO KABUSHIKI KAISHA) having a thickness of 40 .mu.m
was used. The other configuration was made the same as that of
example 1, thereby preparing a back side protective sheet 10 for a
solar cell.
Example 4
[0046] As an interposing resin layer 113, a methacrylate resin
(SUMIPEX manufactured by Sumitomo Chemical Company, Limited) was
used. The other configuration was made the same as that of example
1, thereby preparing a back side protective sheet 10 for a solar
cell.
Comparison Example 1
[0047] Film formation was conducted by means of the T-die extruder
used in example 1 by employing a co-extrusion method, and as shown
in FIG. 3, a first film 11 was prepared such that thicknesses of a
linear low-density polyethylene layer 111 and an interposing resin
layer 113 were 100 .mu.m and 100 .mu.m, respectively. As an
interposing resin layer 113, cycloolefin polymer (ZEONOR
manufactured by ZEON CORPORATION) was used. Next, polyvinyl
fluoride (PVF) (Tedlar manufactured by DuPont Co., Ltd.) having a
thickness of 38 .mu.m was used as a second film 12. A side of the
first film 11 on a side of the interposing resin layer 113 and the
second film 12 were bonded by using a dry laminating adhesive and
employing a dry lamination method in the same manner as in example
1, thereby preparing a back side protective sheet 10 for a solar
cell.
Comparison Example 2
[0048] To 100 parts by mass of a polyethylene resin (ULTZEX
manufactured by Mitsui Chemicals, Inc.) having a density of 0.93
g/cm.sup.3, 4.5 parts by mass of titanium oxide particles having an
average particle diameter of 0.3 .mu.m were added and the resultant
was sufficiently kneaded, thereby preparing a linear low-density
polyethylene composition. Film formation of this linear low-density
polyethylene composition was conducted by means of a T-die
extruder, thereby forming film which a linear low-density
polyethylene layer 111 having a thickness of 50 .mu.m constitutes.
As shown in FIG. 4, the film constituted of the linear low-density
polyethylene layer 111 and a PET film (manufactured by TOYOBO CO.,
LTD.) 114 having a thickness of 125 .mu.m were bonded by using a
dry laminating adhesive and employing a dry lamination method,
thereby preparing a first film 11. As a adhesive layer 13, a
polyurethane-based adhesive obtained by mixing 100 parts by mass of
"product name: TAKELAC A315" and 10 parts by mass of "product name:
TAKENATE A50", both of which were manufactured by Mitsui Chemicals
Polyurethanes Co., Ltd., was prepared with a solid content coated
amount of 5 g/m.sup.2.
[0049] Next, a side of the first film 11 on a side of the PET film
114 and the second film 12 were bonded by using a dry laminating
adhesive and employing a dry lamination method in the same manner
as in example 1, thereby preparing a back side protective sheet 10
for a solar cell.
REFERENCE EXAMPLE
[0050] To 100 parts by mass of a polyethylene resin (ULTZEX
manufactured by Mitsui Chemicals, Inc.) having a density of 0.93
g/cm.sup.3, 4.5 parts by mass of titanium oxide particles having an
average particle diameter of 0.3 .mu.m were added and the resultant
was sufficiently kneaded, thereby preparing a linear low-density
polyethylene composition. Film formation of this linear low-density
polyethylene composition was conducted by means of a T-die
extruder, thereby forming a back side protective sheet for a solar
cell, which only a linear low-density polyethylene film having a
thickness of 200 .mu.m constitutes.
[0051] A weather resistance of each of the back side protective
sheets 10 for solar cells prepared as described above was evaluated
as follows.
[0052] (Weather Resistance I)
[0053] With respect to the back side protective sheet 10 for a
solar cell in each of examples 1 through 4 and comparison examples
1 through 2, a peel strength between the first film 11 and the
second film 12 was measured in conformity with a T-type peel test
of JIS K6854 at a peel rate of 100 mm/minute. Here, a width of a
test specimen was 15 mm. From a value (A) of a peel strength
measured immediately after the preparation of each test specimen
and a value (B) of a peel strength measured after each test
specimen had been retained under conditions of a pressure cooker
test (a temperature of 120.degree. C., a relative humidity of 100%,
and a pressure of 2 atmospheres) for 100 hours, a peel strength
retention [%] was calculated by using the following equation.
Peel strength retention [%]={(B-A)/A}.times.100
[0054] These percentages of the peel strength retention were
evaluated as Weather Resistance I.
[0055] (Weather Resistance II)
[0056] With respect to the first film 11 in the back side
protective sheet 10 for a solar cell in each of examples 1 through
4 and the back side protective sheet for a solar cell in reference
example (the linear low-density polyethylene film alone), a
moisture proof property (water vapor permeability) was measured in
conformity with a humidity sensor method of JIS K7129: 2008 by
means of a L80-5000 model manufactured by PBI-Dansensor.
[0057] (Weather Resistance III)
[0058] A moisture proof property (water vapor permeability) of the
whole of each of the back side protective sheets 10 for solar cells
was measured as in the same manner as in the measurement of the
above-mentioned weather resistance II. From a value (C) of a water
vapor permeability measured immediately after the preparation of
each test specimen and a value (D) of a water vapor permeability
measured after each test specimen had been retained under
conditions of a pressure cooker test (a temperature of 120.degree.
C., a relative humidity of 100%, and a pressure of 2 atmospheres)
for 100 hours, each water vapor permeability change rate [%] was
calculated by using the following equation.
Water vapor permeability change rate [%]={1-(D/C)}.times.100
[0059] These water vapor permeability change rates were evaluated
as Weather Resistance III. The values of the water vapor
permeability change rates which are positive indicate that the
water vapor permeabilities were decreased after the pressure cooker
test, and the values of the water vapor permeability change rates
which are negative indicate that the water vapor permeabilities
were increased after the pressure cooker test.
[0060] The results described above are shown in Table 1.
TABLE-US-00001 TABLE 1 Weather Weather Weather Resistance I
Resistance II Resistance III [%] [g/m.sup.2-24 hours] [%] Example 1
-2.8 1.5 +6.3 Example 2 -2.0 1.2 +1.4 Example 3 -2.8 0.8 +5.0
Example 4 -3.8 1.5 -5.0 Comparison -58.6 -- -6.3 Example 1
Comparison -84.3 -- -43.0 Example 2 Reference -- 3.6 -- Example
[0061] It is seen from the results shown in Table 1 that in the
back side protective sheet 10 for a solar cell in each of examples
1 through 4 according to the present invention, even after the
accelerated life test for the moisture resistance evaluation, the
peel strengths of the first and second films are favorably
maintained and the moisture proof property is also favorably
maintained, as compared with the back side protective sheet 10 for
a solar cell in each of comparison examples 1 through 2.
Accordingly, it is seen that the back side protective sheet 10 for
a solar cell in each of examples 1 through 4 according to the
present invention can maintain a weather resistance over a long
period of time, as compared with the back side protective sheet 10
for a solar cell in each of comparison examples 1 through 2.
[0062] The described embodiment and examples are to be considered
in all respects only as illustrative and not restrictive. It is
intended that the scope of the invention is, therefore, indicated
by the appended claims rather than the foregoing description of the
embodiment and examples and that all modifications and variations
coming within the meaning and equivalency range of the appended
claims are embraced within their scope.
INDUSTRIAL APPLICABILITY
[0063] A back side protective sheet for a solar cell according to
the present invention is disposed on a back side of a solar cell
module to be used, is capable of enhancing adherence between an EVA
resin as filler used to seal solar cell elements and the back side
protective sheet, and allows a weather resistance to be maintained
over a long period of time.
REFERENCE SIGNS LIST
[0064] 10: back side protective sheet for a solar cell, 11: first
film, 12: second film, 13: adhesive layer, 100: solar cell module,
111, 112: linear low-density polyethylene, 113: interposing resin
layer.
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